opelstr. 3 germany - interroll group · 2control input 19400 v ac (input or looping through)...

INSPIRED BY EFFICIENCY

IEC / EN 60947

IP54

3x400VAC / 3A

,

24VDC / 2A

In: www.interro

ll.com

Germany

–

Hückelhoven

41836

GmbH

Trommelm

otoren

Interroll36/2

017

000001234

1112827

User Manual

Interroll Pallet ControlPC 6000

Version 1 (07/2017) enTranslation of original instruction manual

Manufacturer

Interroll Trommelmotoren GmbHOpelstr. 3 41836 Hueckelhoven/Baal Germany Phone: +49 2433 44 610

www.interroll.com

Contents

We strive for the information presented to be correct, up to date and complete. We havecarefully worked out the contents of this document. However, we assume no liability forthe information. We expressly deny any liability for damages or consequential damagesthat are connected in any form with the use of this document. We reserve the right tochange the documented products and product information at any time.

Copyright / intellectual property right

Texts, images, graphics and the like as well as their arrangement are protected bycopyright and other protection laws. Reproduction, modification, transfer or publicationof any part or the entire content of the document in any form is prohibited. Thisdocument is intended exclusively for information purposes and for intended use and doesnot authorize replicating the respective products. All signs contained in this document(registered trademarks, such as logos and business designations) are the property ofInterroll Trommelmotoren GmbH or third parties and may not be used, copied ordistributed without prior written consent.


Interroll Pallet Control PC 6000


3

Table of contentsIntroduction............................................................................................................................ 5

Information about the manual .............................................................................................................. 5Contents............................................................................................................................................... 5The manual is part of the product................................................................................................ 5

Warning notices in this manual ............................................................................................................ 5Symbols....................................................................................................................................................... 5

Safety ..................................................................................................................................... 6State of the art.......................................................................................................................................... 6Intended use .............................................................................................................................................. 6Personnel qualification ............................................................................................................................ 7

Operators ........................................................................................................................................... 7Qualified person ............................................................................................................................... 7Electricians........................................................................................................................................... 7

Dangers....................................................................................................................................................... 7Bodily injury ........................................................................................................................................ 7Electricity.............................................................................................................................................. 7Working environment ...................................................................................................................... 7Faults during operation ................................................................................................................... 7Maintenance....................................................................................................................................... 7Accidental motor start ..................................................................................................................... 7

Interfaces to other devices..................................................................................................................... 8Operating modes ..................................................................................................................................... 8

Normal mode..................................................................................................................................... 8Special mode...................................................................................................................................... 8

Product information.............................................................................................................. 9Product description .................................................................................................................................. 9Overview of the functions...................................................................................................................... 9Structure ..................................................................................................................................................... 10Internal connections ................................................................................................................................. 11Scope of delivery ..................................................................................................................................... 11Type plate................................................................................................................................................... 12Technical Data........................................................................................................................................... 12Dimensions.................................................................................................................................................. 13

Transport and storage .......................................................................................................... 14Transport..................................................................................................................................................... 14Storage ....................................................................................................................................................... 14

Assembly and installation ................................................................................................... 15Warning notices for installation............................................................................................................ 15Installation .................................................................................................................................................. 15Warning notices concerning the electrical installation ................................................................... 16Electrical installation ................................................................................................................................ 17

X1 and X2: Outputs for 400 V line voltage and motors ....................................................... 19X3 and X4: Control inputs .............................................................................................................. 20


Table of contents

4 Version 1 (07/2017) enTranslation of original instruction manual

Initial startup and operation................................................................................................ 22Checks before the initial startup .......................................................................................................... 22Start ............................................................................................................................................................. 22Startup characteristics............................................................................................................................. 23Parameter sets ........................................................................................................................................... 23Current measurement ............................................................................................................................. 23Temperature sensor ................................................................................................................................. 23LED indicators............................................................................................................................................ 24Configuration options ............................................................................................................................. 24

Configuration via USB ..................................................................................................................... 24Configuration with the magnetic sensor ..................................................................................... 27

Operation................................................................................................................................................... 29Checks before each startup ........................................................................................................... 29Start ...................................................................................................................................................... 29Stop....................................................................................................................................................... 29

Maintenance and cleaning.................................................................................................. 30Warning notices concerning maintenance and cleaning............................................................... 30Maintenance.............................................................................................................................................. 30

Checking the Pallet Control ............................................................................................................ 30Replacing the Pallet Control ........................................................................................................... 30

Cleaning...................................................................................................................................................... 30

Decommissioning and disposal .......................................................................................... 31Shutdown.................................................................................................................................................... 31Disposal....................................................................................................................................................... 31

Troubleshooting..................................................................................................................... 32Meaning of the LEDs ............................................................................................................................... 32Error signaling ........................................................................................................................................... 33

Appendix ............................................................................................................................... 34Declaration of Conformity ..................................................................................................................... 34



5

Introduction

Information about the manualContents This instruction manual contains important notes and information about the various operating

phases of the Pallet Control.

The instruction manual describes the product as it is delivered by Interroll.

In addition to this instruction manual, special contractual agreements and technical documentsapply to special versions.

The manual is part of theproduct

4 For trouble-free, safe operation and compliance with possible warranty claims, read themanual first and follow the instructions.

4 Keep the manual close to the product.4 Pass the manual on to any subsequent operator or owner.4 NOTICE! The manufacturer does not accept any liability for faults or defects due to

non-observance of this instruction manual.4 If you have any questions after reading the operating instructions, please contact the Interroll

customer service. Contact persons close to you can be found on the Internet underwww.interroll.com/contact.

Warning notices in this manualThe warning notices refer to risks that may arise while using the product. They are available infour danger levels identified by the signal word:

Signal word Meaning

DANGER Identifies a danger with high risk that will result in death or serious injury if itis not avoided.

WARNING Identifies a danger with medium risk that could result in death or seriousinjury if it is not avoided.

CAUTION Identifies a danger with low risk that could result in minor or medium injuryif it is not avoided.

NOTICE Identifies a danger that results in property damage.

Symbols

This symbol marks useful and important information.

Requirement:R This symbol represents a prerequisite to be met prior to assembly and maintenance work.

4 This symbol marks the steps to be carried out.



Safety

State of the artThe product has been built to comply with the state of the art and is reliable in operation asdelivered. Nevertheless, hazards may arise during its use.

Disregarding the notices in this manual may lead to serious injury.4Carefully read the manual and follow its content.

Intended usePallet Control may only be used for industrial applications and in an industrial environment tocontrol one or two Interroll Pallet Drive.

The product must be integrated into a conveyor module or conveyor system. Any other use isconsidered inappropriate.

Any modifications that affect the safety of the product are not permitted.

The product may only be operated within the defined operating limits.

Applications outside these limits require the approval of Interroll.


Safety


7

Personnel qualificationUnqualified personnel cannot recognize risks and, as a result, is subject to greater dangers.

4 Authorize only qualified personnel to perform the activities described in these instructions.4 The operating company must ensure that personnel follow locally applicable regulations and

rules about safety and hazards while working.

The following target groups are addressed in these instructions:

Operators Operators have been instructed in the operation and cleaning of the product, and follow thesafety guidelines.

Qualified person A specialist is a person who, based on his relevant technical training, education and experience,is capable of detecting risks and avoiding dangers that could occur during the use of theproduct.

Electricians Persons working on electrical installations must have the pertinent technical training. They requiresuitable training, suitable education and experience that enables them to detect risks and avoiddangers which could originate from the electricity. (IEC 60204-1)

Dangers

The following list informs you about the various types of danger or damage that may occurwhile operating the product.

Bodily injury 4 Work on the device must be performed only by authorized electricians in accordance withapplicable regulations.

4 Before using the product, ensure that no unauthorized personnel is in the vicinity of theconveyor.

Electricity 4 Only perform installation and maintenance work when powered down.4 Before working on the device, ensure that both voltages (400 V AC and 24 V DC) have

been switched off. DANGER! 400 V could be applied, even though the LEDs are noton, since the device is supplied by two power sources.

4 Secure the device against inadvertent activation.

Working environment 4 Do not use the product in explosive environments.4 Remove material that is not required and unnecessary objects from the workspace.

Faults during operation 4 Regularly check the product for visible damage.4 If you notice smoke, switch off the power immediately and ensure that it cannot be switched

on again accidentally.4 Immediately contact an electrician and have that person determine the cause of the fault.

Maintenance 4 Because the product does not require maintenance, you only need to inspect all componentsregularly for visible damage and check that all cables and screws are firmly in place.

Accidental motor start 4 Ensure that a connected motor cannot start accidentally, particularly for assembly,maintenance work and troubleshooting.


Safety


Interfaces to other devicesHazard zones may occur while installing the product in a complete system. These zones are notpart of this manual and have to be analyzed during the design, installation and startup of thecomplete system.

4 After installing the product in a conveyor system, check the complete system for newpotential hazard zones before switching on the conveyor.

4 Additional construction measures may be required.

Operating modesNormal mode Operation of the installed device at the end customer's as a component in a conveyor in a

complete system.

Special mode Special operation refers to all operating modes which are required to guarantee and maintainregular operation.

Special operating mode Explanation Comment

Transport/storage Loading and unloading, transport and storage -

Assembly/Initial start-up Installation at the end customer and performing the test run -

Cleaning External cleaning without removing protective devices In the de-energized state

Maintenance/Repairs Maintenance and inspection tasks In the de-energized state

Troubleshooting Troubleshooting in the event of a fault -

Fault elimination Eliminating the fault In the de-energized state

Decommissioning Removing from the complete system In the de-energized state

Disposal Removing from the complete system and disassembly In the de-energized state



9

Product information

Product descriptionPallet Control is a decentralized control for conveyor systems that allows for operating up to twoPallet Drive. Pallet Control can be controlled as follows:

• via a RollerDrive control system, such as MultiControl• PLC• directly via the digital inputs

By combining Pallet Control with a RollerDrive control system, it is possible, among other things,to implement zero pressure accumulation conveying of pallets. It is also possible to control PalletDrive with integrated brakes.

Various protective mechanisms are integrated, such as analysis of the thermal contact andoverload detection. Error messages are signaled via LEDs that show different flashing patternsdepending on the malfunction.

Overview of the functions• Simultaneous control of two 400 V Interroll Pallet Drive• Looping-through of line voltage (400 V AC) possible• Integrated holding brake control (24 V DC)• Adapting Interroll RollerDrive control systems possible (MultiControl, ConveyorControl)• Alternate control via PLC possible• Soft start and soft stop, parameters can be assigned• Controlled stopping length of pallet, parameters can be assigned• Integrated current limit and operating hour counter• Parameterization via USB port possible• Parameterization and error acknowledgment with magnetic key possible• Several parameter sets possible• Output of error messages via LEDs


Product information


Structure

IEC / EN 60947IP54 3x400VAC / 3A, 24VDC / 2AIn:

www.interroll.comGermany–Hückelhoven41836

GmbHTrommelmotorenInterroll

36/2017

0000012341112827

Pallet Drive 1

Pallet Drive 1

Modus Hold 1

Status

Error

24VDC

400V

USB

Pallet Drive 2

Pallet Drive 2

Modus Hold 2

Input 1

Pallet Controlfor Pallet Drive

400VAC

431 2 6 875

9 101213 11

1 Pallet Drive output 8 Pallet Drive 2 output2 Control input 1 9 400 V AC (input or looping through)3 Pallet Drive 1 status LEDs 10 Type plate4 Pallet Control status LEDs 11 Housing screw M55 USB programming port 12 Position for solenoid sensor6 Pallet Drive 2 status LEDs 13 400 V AC (input or looping through)7 Control input 2


Product information


11

Internal connections

X1

X3 X4

X5

X2

X1 Connection for 400 V and Pallet Drive 1 X4 Connection for Pallet Drive 2 controlsignals

X2 Connection for 400 V and Pallet Drive 2 X5 USB port for Pallet Control configuratorX3 Connection for Pallet Drive 1 control

signals

Scope of deliveryThe Pallet Control's scope of delivery contains the following components:

• Pallet Control circuit board and housing• 2 x PG screw connection M20 (already installed)• 2 x PG screw connection M16 (already installed)• 2 x PG screw connection M12 (already installed)• 2 round cables with M8 coupling (already installed)• 3 miniature fuses 3A (already inserted)• 1 dummy plug M20 (required if 400 V output is not used)• 1 dummy plug M16 (required for operation with one motor only)• Packaging


Product information


Type plateThe information on the type plate is used to identify the Pallet Control.




36/2017

0000012341112827

2

1

34

8

7

6

5

Type plate for Pallet Drive

1 Serial number 5 Connection data2 CE mark 6 Manufacturer3 Product standard 7 Date of manufacture4 IP protection rate 8 Article number

Technical Data

Rated voltage 3 x 400 V AC 50 Hz; 24 V DC

Temporarily permissible voltage range 380 – 420 V AC 50 Hz; 22.8 – 25.2 V DC

Current consumption max. 3 A @ 400 V AC; max. 2 A @ 24 V DC

Protection rate IP54

Weight 0,5 kg

Ambient temperature in operation -28 °C to +40 °C (-22 °F to +104 °F)

Ambient temperature during transport andstorage

-40 °C to +80 °C (-40 °F to +176 °F)

Max. temperature change 1 K/min, 3 h, 2 cycles (IEC 60068-2-14)

Max. relative humidity Max. 93 % at +40 °C (+104 °F), 14 days,non-condensing (IEC 60068-2-78)

Max. installation height above sea level Max. 1,000 m. Installation in systems at analtitude above 1,000 m (3,300 ft) is possible inprinciple. However, this may result in lowerperformance values.


Product information


13

Dimensions




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0000012341112827

Pallet Drive 1

Pallet Drive 1

Modus Hold 1

Status

Error

24VDC

400V

USB

Pallet Drive 2

Pallet Drive 2

Modus Hold 2

Input 1


400VAC

209

160

97

97

5

5.9

5

Three holes with a diameter of 5.5 mm each for M5 hexagon socket screws are intended forfastening the Pallet Control to the conveyor frame:




36/2017

0000012341112827

Pallet Drive 1

Pallet Drive 1

Modus Hold 1

Status

Error

24VDC

400V

USB

Pallet Drive 2

Pallet Drive 2

Modus Hold 2

Input 1


400VAC

114 Ø5.5

57

85

Drilled holes for fastening



Transport and storage

Transport• Every Pallet Control is packaged in its own cardboard box.

NOTICEThere is a risk of damage to property if transported incorrectly

4 Transport-related tasks should only be carried out by qualified and authorized persons.4 Observe the following notes.

4 Do not stack more than 4 cardboard boxes on top of each other.4 Avoid heavy impacts during transport.4 Inspect each Pallet Control for visible damage after transport.4 In the event of damage, take photos of the damaged parts.4 Report any damage caused by transport immediately to the transport company and to the

Interroll to maintain warranty.4 Do not expose the Pallet Control to large temperature fluctuations as this could result in

condensation.

Storage

NOTICERisk of damage to property due to improper storage

Do not stack more than 4 cardboard boxes on top of each other.

4 Check each Pallet Control for damage after storage.



15

Assembly and installation

Warning notices for installation

NOTICERisk of property damage that may cause failure or shortened service life

4 Check each Pallet Control for damage before installation.4 Ensure that the Pallet Control is not warped during installation (no bending or torsion).4 Do not drill additional mounting holes in the housing or enlarge the holes provided.4 Do not drop the Pallet Control to prevent internal damage.

NOTICEThe protection class IP54 is ensured only with proper installation.

4 Close the housing correctly.4 Firmly tighten cable connectors or, if not used, apply dummy caps.4 Close USB cover.

InstallationThe rear plate features three holes for M5 screws for fastening the Pallet Control to theconveyor frame.

If possible, install all Pallet Controls only on one side of the conveyor system to simplify theelectrical installation.4 Identify a flat area on the conveyor frame where the Pallet Control can be installed.4Ensure that there is sufficient space for the cable entry on the left and right.4Hold the Pallet Control to the conveyor frame and mark the center of the installation holes.

Observe the correct orientation of the housing.4Drill three holes with ø 5.5 mm at the markings in the conveyor frame.4Screw the baseplate onto the conveyor using M5 screws.4Ensure that the rear plate is not twisted.




Warning notices concerning the electrical installation

DANGERDanger – electrocution

Improper electrical installation can cause life-threatening electric shocks or damage to the PalletControl.

4 Only have an electrician undertake electrical installation work.4 Observe national regulations for electrical installation. Within the EU, IEC 60204-1 must be

met at a minimum.4 Before installing, wiring or removing the Pallet Control, switch it off and ensure that it cannot

be started accidentally.4 The Pallet Control may be operated only with AC voltage at a rated voltage of 400 V 50

Hz and 24 V DC and a maximum permissible deviation of ±5 %.4 Proceed with caution when connecting the Pallet Drive to avoid damaging the magnetic

sensor on the printed circuit board.4 Ensure that the control systems, motors and power sources connected to the Pallet Control,

as well as the entire conveyor system, are correctly grounded. Incorrect grounding can resultin the build-up of a static charge, causing the Pallet Control to malfunction or failprematurely.

4 Ensure that the existing electrical installation does not interfere with the Pallet Control.4 Use only cables that are sufficiently dimensioned for the specific operating conditions.4 Do not forget to observe the calculations for voltage drop on electrical lines.4 Observe the regulations for routing cables.4 Use suitable switching equipment and protective devices to ensure safe operation.4 Only apply operating voltages when all cables have been connected.4 Do not apply too much tension or pressure to the plug. When bending the cable at the plug,

the insulation of the cable may be damaged and the Pallet Control may fail.4 Install a suitable protection mechanism so that the Pallet Control and the line are not

overloaded.4 Have an electrician undertake the dimensioning of the protection mechanism.4 When selecting the line protection, pay particular attention to the maximum short circuit

current of the voltage supply.




17

Electrical installation




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Pallet Drive 1

Pallet Drive 1

Modus Hold 1

Status

Error

24VDC

400V

USB

Pallet Drive 2

Pallet Drive 2

Modus Hold 2

Input 1


400VAC

1 1

2 2 3

1 Connection of Pallet Drive 2 Connection of 400 V AC3 Housing screw

4 Loosen the hexagon socket screw (3) located in the center to open the housing. An Allen keysize 4 is required.

4 Strip lines appropriately and remove the insulation along the appropriate length of the line.4 Feed the lines through the provided cable connectors into the device: Size M20 for the 400

V AC supply (2), size M16 for the Pallet Drive (1).4 Remove unused cable connectors and close the openings with the supplied dummy caps to

ensure protection class IP54.4 Connect lines as shown in the terminal diagram. The PE conductor must always be connected.

The clamping of the phases must match the labeling on the clamps.

For the Pallet Drive version without integrated brake, the cores 4, 5 and 6 for the star point mustbe connected with a suitable connecting terminal.

If the power supply connection uses a 5-pole cable with neutral conductor, it must be routed inthe device in such a way that no contact to any live or conducting component is possible.




The Pallet Control is equipped with three replaceable slow-acting miniature fuses of type 5 x 20;3.15 A that are used for device protection (1). Protection of the supply cables must be ensuredby the operator.

1

X1 X2

X3 X4




19

X1 and X2: Outputs for400 V line voltage and

motors

The printed circuit board features one 12-pin circuit board terminal of type WAGO 739 oneach side, left and right. Cores up to 2.5 mm² can be connected here. If wire end sleeves areused, the cross section is limited to 1.5 mm². The M20 cable connectors on the left and right sideof the housing are intended for connection or looping through of the 400 V supply. One 4-corecable each with 7-13 mm outer diameter can be fed into the device.

The M16 cable connectors on the left and right side of the housing are intended for connectingthe Pallet Drive. One 8-core cable each with 4.5-10 mm outer diameter can be fed into thedevice from the Pallet Drive.

The terminal designations are printed on the circuit board.

X1

X3 X4

X5

X2

Designation Function Direction

BR- Holding brake 1 GND Output

BR+ Holding brake 1 +24 V Output

T1 Thermal circuit breaker 1 input Input

T2 Thermal circuit breaker 1 +24 V Output

PE PE Grounding

U Motor1-U Output

V Motor1-V Output

W Motor1-W Output

L1 L1 400 V Input/output



PE PE Grounding

Tab. 1: X1 and X2: Assignment from top to bottom




X3 and X4: Control inputs The top of the circuit board features two 8-pin terminal strips for connecting control signals andthe 24 V DC supply. They are intended for the power supply and to control the operatingbehavior of the Pallet Drive.

The terminal designations are printed on the circuit board.

X1

X3 X4

X5

X2

Designation Function Direction

+ +24 V DC input Supply input

Dir Direction of rotation:• 0 V – 4.0 V = CCW,

counterclockwise• 7 V – 24 V = CW,

clockwise

Input

- GND Supply input

Err Error signal:• 24 V = High = motor fault• 0 V = Low = no fault

Output

Sp Control input:• 0 V – 2 V = stop• 8.5 V – 24 V = start

Analog input

I1 Reserve terminal Input



Tab. 2: X3 and X4: Assignment from inside to outside

When delivered, one 0.5 m long cable with a 5-pin connector of type SAL-8B-RSS5.1 fromConec is pre-installed at both control inputs. It is intended for connecting to the outputs of aRollerDrive control system. If no RollerDrive control system is used, it can be connected to a PLCor similar control system by using an adapter cable.




21

The connector features 5 contacts:

CONEC 5

4 2

13

5-pin connector

Pin cable Core color Function

1 - brown +24 V

2 - white Input direction signal

3 - blue Ground, 0 V

4 - black Output error signal

5 - gray Input control signal

Tab. 3: Pin assignment



Initial startup and operation

Checks before the initial startup4 Ensure that the base plate of the Pallet Control is correctly fastened to the profile.4 Ensure that the Pallet Control is correctly fastened to the base plate.4 Ensure that all screws are properly tightened.4 Ensure that no additional danger zones have been created due to interfaces to other

components.4 Ensure that the wiring is in accordance with the specification and legal requirements.4 Check all protective devices.4 Ensure that there are no persons in the danger zones of the conveyor system.

NOTICEObserve Pallet Drive connection diagrams

Damage to the Pallet Drive or Pallet Control is possible if connections are incorrect.

4 Ensure that the holding brake and thermal circuit breaker connections are correct.

4 Ensure that the status LEDs are on after the power supply has been switched on.

StartAfter a cold start, the Pallet Control requires less than 2 seconds to initialize. During this processthe system also checks whether or not holding brakes are connected.

After each restart, the Pallet Control waits for a travel signal from one of the two inputs of eachmotor.

Avoid frequent changes of direction. At more than 4 changes of direction per minute, the servicelife of the center zero relay is greatly reduced.




23

Startup characteristicsThe Pallet Control features a soft start function to reduce starting torques. These startupcharacteristics can be set by using 3 parameter sets.

Parameterizableramp time

Parameterizablestarting power

Time (t) s

Soft startupNormal startupFast startup

Motor output in %

P 100%

2 s1 s 3 s

Parameter setsThe Pallet Control features three parameter sets:

• Fast startup• Normal startup• Soft startup

Each parameter set has its own values for the following parameters:• Starting power• Ramp time

For configuration with a magnet (see "Configuration options", page 24), one of the three presetparameter sets can be selected. For configuration via USB, it is possible to select a presetparameter set, as well as change its individual parameters.

Both motors can use the same parameter set or different parameter sets.

Current measurementThe Pallet Control measures the current flow of each motor during operation. The currentmeasurement is used for overload detection.

Temperature sensorA temperature sensor is integrated in the Pallet Control to measure the temperature of theprinted circuit board. If the internal temperature of 95 °C is exceeded, all functions are disabledand an error signal is output.




LED indicatorsThe printed circuit board features 8 LEDs that indicate the current operating status. They aretransferred to the front via optical conductors. If there is an error, the LEDs Error and Pallet Driveare flashing. The Pallet Drive LED shows the source of the error and the flashing frequency of theLEDs points to the error. For additional information about error detection, see see"Troubleshooting", page 32.

Pallet Drive 1

Pallet Drive 1

Modus Hold 1

Status

Error

24VDC

USB

Pallet Drive 2

Pallet Drive 2

Modus Hold 2400VAC

Pallet Control LEDs

Configuration options

Configuration via USB USB service port




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Pallet Drive 1

Pallet Drive 1

Modus Hold 1

Status

Error

24VDC

400V

USB

Pallet Drive 2

Pallet Drive 2

Modus Hold 2

Input 1


400VAC

1

1 USB port

The printed circuit board features one USB port type B for connection to a computer. This USBport is used for programming the Pallet Control. It is accessible without opening the housing viaa captive rubber cap. During regular operation the rubber cap should be closed since protectionclass IP54 is met only when it is closed.




25

Pallet Control Configurator

The Pallet Control Configurator is a Windows-based software to monitor and parameterize thePallet Control, as well as the connected Pallet Drive. The connection to the PC is established viathe USB service port. The baud rate or other transmission parameters are automatically set.When it is plugged into a new PC for the first time, Windows prompts for the installation of adriver. This driver is supplied by Interroll together with the Pallet Control Configurator. The PalletControl Configurator is available on the Interroll website in the support section.

The current power, electrical current and direction of rotation are displayed in the main window.In addition, it is possible define the control input used, to change the direction of rotation, and toselect the parameter set to be used.

Configurator user interface




Setting parameter sets

4 Select Configuration > Edit Parameter Sets in the menu.4 Select the parameter set to be edited.4 Set the desired starting power or ramp time.4 Click Save to confirm the changes.

Operating hour counter

4 Select Configuration > Operating times in the menu.

The following operating times are recorded:• Total operating hours• Operating time since last restart• Total active time motor 1• Total active time motor 2• Active time since last restart motor 1• Active time since last restart motor 2• Motor 1 start/stop total• Motor 2 start/stop total




27

Reset to factory setting

4 Select Configuration > Set Factory Defaults in the menu.

ð All settings are returned to the settings at delivery.

Acknowledging an error

4 Select Configuration > Reset Pallet Control in the menu.

ð When the cause of the fault has been removed, the Pallet Control returns to an error-freestate.

Configuration with themagnetic sensor

The following functions can be executed with the help of the magnetic sensor and a magnet:• Restart and reset error• Change the direction of rotation of the motor• Set switch-off ramps in 3 steps• Reset Pallet Control to factory settings

IEC / EN 60947

IP54

3x400VAC / 3A

,

24VDC / 2A

In: www.interro

ll.com

Germany

–

Hückelhoven

41836

GmbH

Trommelm

otoren

Interroll36/2

017

000001234

1112827

2

1

1 Magnetic key 2 Magnetic sensor

Operating the magnetic sensor requires a magnetic key (1), which is available as an accessory.The magnetic sensor (2) is located on the printed circuit board, roughly centered between theError LED and the Modus Hold 1 LED.

Requirement:R Neither motor is running.

4 Hold the magnet to the magnetic sensor for longer than 2 seconds.Configuration starts.

4 Navigate through the menu and change the settings by holding the magnet to the sensor forshorter or longer periods of time.

After every long magnet signal, the magnet must be removed briefly once. After 30 secondswithout magnet detection, the Pallet Control returns to normal mode.




The menu structure for configuration with a magnet is schematically represented below.

v

Motor 1 uses

parameter set 1

Motor 1

Direction Error LED off

Motor 1 LED flashes

Reverse Motor 1

direction

Motor 1

Parameter set 1Error LED flashes 1x

Motor 1 LED flashes

Motor 1

Parameter set 2

Motor 1


Motor 1 LED flashes

Error LED flashes 2x

Motor 1 LED flashes

Motor 1 uses

parameter set 2

Normal

mode

Restart

Selection

Configuration

Motor 1

Error LED flashes

Error code

Error LED

flashes 1x

Error LED off

Motor 1 LED on

Briefly hold magnet at

the sensor

Hold magnet longer

than 2 seconds at the

sensor

Factory settings

Reset


Motor 1 LED flashes

Motor 2 uses

parameter set 1

Motor 2

Direction Error LED off

Motor 2 LED flashes

Reverse Motor 2

direction

Motor 2


Motor 2 LED flashes

Motor 2

Parameter set 2

Motor 2


Motor 2 LED flashes


Motor 2 LED flashes

Motor 2 uses

parameter set 2

Configuration

Motor 2Error LED off

Motor 2 LED on

Motor 2 uses

parameter set 3

Motor 1+2 use

parameter set 1

Motor 1+2

DirectionError LED off

Motor 1+2 LED flash

Reverse Motor 1+2

direction

Motor 1+2


Motor 1+2 LED flash

Motor 1+2

Parameter set 2

Motor 1+2


Motor 1+2 LED flash


Motor 1+2 LED flash

Motor 1+2 use

parameter set 2

Configuration

Motor 1+2Error LED off

Motor 1+2 LED on

Factory

settingsError LED

flashes 2x

Motor 1+2 use

parameter set 3

Menu structure for configuration with a magnetic key




29

Operation

CAUTIONAccidental startup of Pallet Drive

Danger of crushing of limbs and damage to material

4 Ensure that there are no persons in the danger zones of the conveyor system beforeswitching on the power supply.

Checks before eachstartup

4 Check all Pallet Controls for visible damage.4 Check all protection devices.4 Ensure that no Pallet Drive connected to the Pallet Control is blocked.4 Precisely specify and monitor the placement of the material.4 Ensure that there are no persons in the danger zones of the conveyor system.

Start 4 Ensure that ambient conditions are met during operation.4 Switch on the power supply.4 Send the corresponding signal to the Pallet Control.

Stop Conveying stops in the following cases:• If the power supply is switched off.• If no signal for the start is present.• If there is an error in a corresponding error class.



Maintenance and cleaning

Warning notices concerning maintenance and cleaning

CAUTIONRisk of injuries due to incorrect handling

4 Maintenance and cleaning work must only be performed by qualified and authorizedpersons.

4 Perform maintenance work only after switching off power.4 Ensure that the Pallet Control cannot be turned on accidentally.4 Set up signs indicating that maintenance work is in progress.

MaintenanceChecking the Pallet Control

The Pallet Control itself is maintenance-free. To prevent faults however, connections andfastening must be checked in the course of regular inspection and maintenance work:

4 Ensure that the screws of the Pallet Control are still firmly tightened.4 Ensure that the cables are still routed correctly.4 Ensure that the connections are still connected correctly.

Replacing the Pallet Control

If a Pallet Control is damaged, it has to be replaced.

CleaningDust and dirt in combination with humidity may bridge the electric circuit. In dirty environments,periodic cleaning therefore will help to avoid short circuits that could damage the Pallet Control.

NOTICEDamage to the Pallet Control due to incorrect cleaning

4 Do not immerse the Pallet Control in liquids.

4 Vacuum off dust and dirt, if necessary.4 For more thorough cleaning, disconnect the Pallet Control from the power supply, remove it,

and wipe it with a damp cloth.



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Decommissioning and disposal4 When disposing the motor oil, observe the disposal documents of the motor manufacturer.4 The packaging must be recycled to provide environmental relief.

Shutdown

CAUTIONRisk of injuries due to incorrect handling

4 Shut-down may only be executed by qualified and authorized persons.4 Only shut down the Pallet Control after switching off the power.4 Ensure that the Pallet Control cannot be turned on accidentally.

4 Remove all cables from the Pallet Control.4 Unscrew the screws that fasten the Pallet Control to the conveyor.4 Remove the Pallet Control.

DisposalThe operating company is responsible for the proper disposal of the Pallet Control.

4 In doing so, industry-specific and local provisions for the disposal of the Pallet Control and itspackaging must be observed.

4 The packaging must be recycled to reduce the pressure on the environment.



Troubleshooting

Meaning of the LEDsLEDs on the front inform about the operating state of the Pallet Control and the connected PalletDrive

Labeling Function Color

Pallet Drive 1 On: Motor 1 is controlled.Off: Motor 1 is not controlled.

Yellow

Modus Hold 1 On: Holding brake at motor output 1 is not controlledand therefore closed.Off: No holding brake connected at motor output 1 orholding brake is controlled and therefore is open.

Yellow

Status On: The system is ready for operation, 24 V areapplied, 400 V were detected, no other error is present.Flashes briefly 3 times: At every restart.Flashes: During USB connection for configuration.Off: In all other cases.

Green

Error On: Error.Off: No error.

Red

24VDC On: 24 V supply voltage connected.Off: No 24 V supply.

Green

400VAC On: L1, L2 and L3 are connected to the 400 V input andvalid phase crossings with 50 Hz have been detected.Flashing: L1, L2 and L3 are connected to the 400 Vinput.Off: Only one or no 400 V line is connected andtherefore no phase crossings have been detected.

Green

Pallet Drive 2 On: Motor 2 is controlled.Off: Motor 2 is not controlled.

Yellow

Modus Hold 2 On: Holding brake at motor output 2 is not controlled.Off: No holding brake connected at motor output 2 orholding brake is controlled and therefore is open.

Yellow


Troubleshooting


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Error signalingThe Pallet Control features integrated error detection that monitors the operating behavior ofthe Pallet Control and the connected Pallet Drive.

The following options are available to reset an error:• Using the software (see "Configuration via USB", page 24)• Using the magnetic key (see "Configuration with the magnetic sensor", page 27)• By briefly switching off the 24 V DC control voltage

The following error codes are possible:

Error Possible cause Solution

Error LED flashes 1x Pallet Drive thermal circuitbreaker tripped

4Allow motor to cool off.

Error LED flashes 2x 400 V not detected 4Check 400 V power supply.

Error LED flashes 3x Excessive current detected 4Check whether an overloadis present.

Error LED flashes 4x Holding brake defective 4Check holding brakeconnections.

Error LED flashes 5x Excessive temperature on theprinted circuit board

4Call Interroll service.

Error LED flashes 6x Triac detected as defective 4Call Interroll service.

Error LED flashes 7x 24 V outside tolerance 4Check DC supply voltage.

Motor does not turn, StatusLED is off

Power supply not connectedcorrectly

4Check power supply.

Motor does not turn, ErrorLED is off

• Motor connections orholding brake cabledincorrectly

• Polarity of holding brakereversed

4Check motor connections.4 Check holding brake

connections.

Magnetic sensor no longerresponds

Magnetic sensor damaged 4Switch 24 V off and onagain.

4 Call Interroll service.

Only Modus Hold 1 andModus Hold 2 are on

Pallet Control constantly inconfiguration mode

4Call Interroll service.

The error "400 V not detected" is deleted automatically after the first occurrence after a reset.After the second occurrence, it is retained and must be deleted manually.



Appendix

Declaration of ConformityIn accordance with EU Directive 2014I3OIEU (Electromagnetic Compatibility) dated February26, 2014

The manufacturer:Interroll Trommelmotoren GmbHOpelstr. 3 D - 41836 Hueckelhoven/BaalGermany

hereby declares that the product

• Pallet Control

meets the requirements of the directives and standards listed below:

Applied EU Directives:• 2014/35/EU EMC• 2011/65/EU RoHS Directive

Person authorized to prepare the technical documents: Holger Hoefer, Interroll Trommelmotoren GmbH, Opelstr. 3, D - 41836 Hueckelhoven, Germany

Hueckelhoven – October 04, 2017

Dr. Hauke Tiedemann (managing director)

(This declaration of conformity can be obtained at www.interroll.com, if needed.)



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